WO2023115752A1 - 大型l形中空薄壁管道的模锻成形模具及模锻成形方法 - Google Patents

大型l形中空薄壁管道的模锻成形模具及模锻成形方法 Download PDF

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WO2023115752A1
WO2023115752A1 PCT/CN2022/085530 CN2022085530W WO2023115752A1 WO 2023115752 A1 WO2023115752 A1 WO 2023115752A1 CN 2022085530 W CN2022085530 W CN 2022085530W WO 2023115752 A1 WO2023115752 A1 WO 2023115752A1
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Prior art keywords
die
section
horizontal
forging
shaped hollow
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PCT/CN2022/085530
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English (en)
French (fr)
Inventor
郑建能
易泓宇
孙嫘
毛闯
袁学飞
李福海
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二重（德阳）重型装备有限公司
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Publication of WO2023115752A1 publication Critical patent/WO2023115752A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J13/00—Details of machines for forging, pressing, or hammering
    • B21J13/02—Dies or mountings therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/08—Upsetting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21J—FORGING; HAMMERING; PRESSING METAL; RIVETING; FORGE FURNACES
    • B21J5/00—Methods for forging, hammering, or pressing; Special equipment or accessories therefor
    • B21J5/06—Methods for forging, hammering, or pressing; Special equipment or accessories therefor for performing particular operations
    • B21J5/10—Piercing billets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K1/00—Making machine elements
    • B21K1/14—Making machine elements fittings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K27/00—Handling devices, e.g. for feeding, aligning, discharging, Cutting-off means; Arrangement thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
    • B21K29/00—Arrangements for heating or cooling during processing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E30/00—Energy generation of nuclear origin
    • Y02E30/30—Nuclear fission reactors

Definitions

  • the invention belongs to the field of die forging, in particular to a die forging forming die and a die forging forming method for a large L-shaped hollow thin-walled pipe.
  • the large L-shaped hollow thin-walled pipe is the core component of the power plant that drives the coolant circulation in the nuclear reactor. Its structure is shown in Figure 1, including the vertical section of the pipe and the horizontal section of the pipe. Turning, there is no large fillet transition at the turning, the cross-section is sudden, the shape is irregular, the entire pipe wall is thin and the size is large, and the weight reaches 1t, which is very difficult to manufacture.
  • the L-shaped hollow thin-walled pipe is an L-shaped pipe whose wall thickness is less than or equal to 1/3 of the diameter of the vertical section of the pipe.
  • the traditional manufacturing method of this large L-shaped hollow thin-walled pipe is to manufacture cast steel ingots by free forging.
  • this manufacturing method it is difficult to forge through and compact the forging itself, and the inner cavity cannot be forged.
  • invisible increase Enlarging the effective section of the forging increases the quality risk of the forging; on the other hand, increasing the ingot shape of the steel ingot also leads to a decrease in material utilization, a large amount of cutting after forging, and an increase in the manufacturing cost and cycle of forgings.
  • a large L-shaped hollow thin-walled pipe forging is formed through a mold.
  • the large L-shaped hollow thin-walled pipe forging 7 and the large L-shaped The hollow thin-walled pipes are similar in shape, and the large L-shaped hollow thin-walled pipe forging 7 includes a vertical section 7A and a horizontal section 7B perpendicular to each other, and a vertically downwardly recessed blind hole 7C is arranged on the vertical section 7A.
  • the application number is CN202110006778.3
  • the name is an invention patent application for a super-large right-angle elbow die forging forming die and die forging forming method, which discloses a super-large right-angle elbow die forging forming process.
  • it designs the shape of the blank; uses a special mold to forge the blank before forming; puts the blank into another specially made cavity, and passes the upsetting rod and side plug , form the horizontal section of the forging, and prefabricate the vertical section; then use the punch to form the vertical section of the forging with blind holes, and then perform quenching and tempering heat treatment, semi-finishing, flaw detection and finishing in sequence to obtain the right-angle elbow.
  • This patent only provides a method for forming a right-angled elbow, and cannot accurately control the size control of the end face of the forging in the horizontal section and the vertical section.
  • a plug is provided on the end face of the horizontal nozzle to prefabricate the horizontal hole, and the plug is set as an eccentric structure on the downward end face, but this structure will also greatly affect the filling effect on the upper side of the horizontal nozzle. Make the upper edge of the horizontal nozzle form a very large natural arc, resulting in a lack of meat in the blank.
  • the patent has provided a compensation structure on the end face at the same time (increasing the diameter of the die cavity within the compensation range of the end face), the effect of alleviating the lack of meat in the blank is very small; In this case, it can show a better end face condition, but it ignores the thin wall case, the end face will form a horseshoe shape due to the difference in friction conditions, resulting in a lack of meat in the forging blank on the low side.
  • the purpose of the present invention is to solve the problem of forming large-scale L-shaped hollow thin-walled pipes and the problem of precise control of the end face dimensions of the vertical section and the horizontal section, greatly improve the utilization rate of materials, and realize the precise forming of L-shaped hollow thin-walled pipes.
  • a large-scale L-shaped hollow thin-walled pipe forging forming die including a bottom die, a pier thick bar and a punch rod, and the bottom die is provided with the outline shape of the L-shaped hollow thin-walled pipe blank Matching die cavity
  • the thick piers include planar thick piers and inclined-plane thick piers arranged independently of each other, the forging working surface of the flat thick piers is a horizontally arranged plane; the inclined-plane thick
  • the die forging working surface of the pier thick bar is an inclined plane, and along the vertical direction, the die forging working surface of the inclined plane type pier thick bar is from the corresponding side with the inner side of the die cavity of the bottom mold to the corresponding side with the outer side of the die cavity of the bottom die. The side slopes down to set.
  • the bottom mold includes an inner mold and an outer mold, and the outer mold is set outside the inner mold;
  • the die chamber is arranged in the inner mold, including a vertical die chamber section whose top end passes through the inner mold top wall vertically and a horizontal die chamber section whose outer end passes through the inner mold side wall; the horizontal die chamber section
  • the outer end of the outer mold extends to the inner surface of the outer mold, the inner surface of the outer mold is a vertical plane, and the inner surface of the outer mold blocks the outer end of the horizontal die cavity section to form a horizontal section forming area.
  • the length of the horizontal cavity section of the inner mold is L1
  • the height difference between the highest point and the lowest point of the die forging working surface of the inclined-plane type pier thick bar is 50-100 mm.
  • the steel ingot with as-cast structure is upset, and after upsetting, it is solidly elongated. After the elongation is completed, the part with better quality is taken to obtain a cylindrical billet;
  • the cylindrical blank is processed to obtain a blank.
  • the blank is cylindrical, and the outer periphery of the lower end surface of the blank is rounded, and the diameter of the rounded corner is 1/5-1/4 of the diameter of the blank; the outer periphery of the upper end surface of the blank is provided with chamfers.
  • the reduction is 30-50mm
  • the spread and press into the anvil is 1/4-1/3 of the diameter of the vertical section
  • the natural fillet formed by the outer end surface of the horizontal section makes the forging The size of the horizontal section meets the requirements of the finished forging.
  • the beneficial effects of the present invention are: the precision forming method of large-scale L-shaped hollow thin-walled pipes disclosed by the present invention uses planar pier thick rods for preliminary pier thickening and then uses inclined-plane type pier thick rods for fine pier thickening, so that the end face of the vertical section Accurate control is obtained; the blank is filled with the horizontal die cavity section after forming the planar pier thick rod, the inclined pier thick rod and the punch rod, so that the end face of the horizontal section is precisely controlled, thereby realizing the precise forging of L-shaped hollow thin-walled pipe forgings Forming, to achieve near-net shape, improve the utilization rate of materials, reduce manufacturing costs, and greatly shorten the manufacturing cycle.
  • the structure of the original steel ingot becomes dense after being elongated by upsetting. Subsequent compression is carried out on the end face of the horizontal section, which increases the degree of deformation of each part, strengthens the compaction effect, and reduces the quality risk of the forging.
  • Fig. 1 is the sectional view of large-scale L-shaped hollow thin-walled pipeline
  • Figure 2 is a sectional view of a large L-shaped hollow thin-walled pipe forging
  • Fig. 3 is the schematic diagram of the die forging forming die structure of large-scale L-shaped hollow thin-walled pipeline
  • Fig. 4 is blank schematic diagram
  • Fig. 5 is the schematic diagram that adopts die forging molding die of the present invention to carry out preliminary pier;
  • Fig. 6 is the schematic diagram that adopts die forging molding die of the present invention to carry out secondary pier thickening
  • Fig. 7 is the schematic diagram that adopts die forging molding die of the present invention to carry out punching
  • Figure 8 is a schematic diagram of L0 marking
  • Figure 9 The front view of the horizontal section heating
  • Fig. 10 Front view of the end surface of the horizontal section
  • Fig. 11 is a right side view of Fig. 10 .
  • planar pier thick rod 1 inclined-plane pier thick rod 2
  • punch rod 3 inner mold 4
  • vertical mold cavity section 4A horizontal mold cavity section 4B
  • outer mold 5 blank 6
  • fillet 6A inverted Angle 6B
  • forging 7 vertical section 7A, horizontal section 7B, blind hole 7C, upper flat anvil 8, heating device 9.
  • the die forging forming die of large-scale L-shaped hollow thin-walled pipeline as shown in Figure 3, comprises bottom mold, pier thick bar and punch 3, and described bottom mold is provided with the outline shape corresponding to the outline shape of L-shaped hollow thin-walled pipeline blank.
  • the thick piers include planar thick piers 1 and inclined plane thick piers 2 that are arranged independently of each other, and the forging working surface of the flat thick piers 1 is a plane arranged horizontally;
  • the die forging working surface of the inclined-plane type pier thick bar 2 is a plane inclined to be arranged, and along the vertical direction, the die forging working surface of the inclined-plane type pier thick bar 2 is from the corresponding side with the inner side of the die cavity of the bottom die to the die forging with the bottom die.
  • the corresponding side outside the bore is arranged obliquely downward.
  • the die forging forming die for large L-shaped hollow thin-walled pipes disclosed by the present invention is provided with a planar pier thick rod 1 with a horizontal plane on the die forging face and an inclined plane on the die forging face
  • the inclined-plane thick pier bar 2 cooperates with the work, and the planar thick pier bar 1 can be used to initially pier thickly, the vertical section 7A and the horizontal section 7B of the prefabricated forging 7, and then the inclined-plane type thick pier bar 2 is used to pier thickly, so that The top surface of the vertical section 7A is inclined downward from the inside to the outside to make up for the difference in friction conditions on both sides, so that in the subsequent punching forming process of the punch 3, the horseshoe-shaped degree of the end surface of the vertical section after punching is relieved. , try to make the billet flow upward to the same height, so that the end face size of the vertical section 7A can be precisely controlled.
  • the outer end of the horizontal die cavity section 4B of the inner mold 4 is provided with a plug, which will make the upper edge of the horizontal section 7B of the forging 7 form a larger natural arc, resulting in The outer end of the horizontal section 7B lacks meat.
  • the bottom mold includes an inner mold 4 and an outer mold 5, and the outer mold 5 is set outside the inner mold 4.
  • the mold chamber is arranged in the inner mold 4, including a vertical mold chamber section 4A whose top end vertically passes through the top wall of the inner mold 4 and a horizontal mold chamber section 4B whose outer end runs through the side wall of the inner mold 4;
  • the outer end of the horizontal die cavity section 4B extends to the inner surface of the outer mold 5, the inner surface of the outer mold 5 is a vertical plane, and the outer end of the horizontal die cavity section 4B is blocked by the inner surface of the outer mold 5 Constitute the forming area of the horizontal section.
  • the natural fillet formed at the end of the horizontal section 7B will be greatly reduced than when the plug is installed, which is more conducive to eliminating the horizontal section 7B.
  • the natural fillet formed by the end face is more conducive to eliminating the horizontal section 7B.
  • the length of the horizontal die cavity section 4B of the inner mold 4 is equal to the length of the horizontal section of the forging, it will definitely cause the blank to lack meat.
  • the length of the horizontal die section 4B of the inner mold 4 is L1
  • the height difference between the highest point and the lowest point of the die forging working surface of the inclined-plane type thick pier bar 2 is 50-100mm.
  • the forging 7 and the forging die are designed according to the structural features of the large L-shaped hollow thin-walled pipeline; the forging 7 includes a vertical section 7A, a horizontal section 7B and a blind hole 7C arranged in the vertical section 7A.
  • the L0 is the stroke required for the planar pier thick rod 1 to pier the blank 6 so that the horizontal die cavity section 4B is just completely filled;
  • Adopt inclined-plane type pier thick rod 2 to replace plane type pier thick rod 1 to carry out fine pier thick, fine pier thick stroke is 100mm, makes the top end surface of vertical section be to have the inclined-plane that gradually slopes downward from inside to outside;
  • the lower movable platform moves down to the lowest position, the planar pier thick bar 1 is separated from the inner mold 4, and the upper movable platform slides to the left so that the inclined-plane-shaped pier thick bar 2 coincides with the central axis of the vertical section of the inner mold 4, and the inclined-plane-shaped pier thick bar
  • the bottom surface of 2 is the low point of the bottom surface relative to the inner mold 4 outsides, and is the low point high point of the bottom surface relative to the inner mold 4 inboards.
  • the lower movable platform moves upwards so that the thick bar 2 of the inclined plane pier extends into the inner mold 4, and performs in-mold upsetting on the formed blank.
  • the end face of the vertical section 7A is prefabricated into a high slope on the inside and a low slope on the outside, as shown in Figure 6,
  • the lower movable platform moves down to the lowest position, the thick bar 2 of the inclined-plane pier is separated from the inner mold 4, the upper movable platform slides to the left to make the punch 3 coincide with the center axis of the vertical section of the inner mold 4, and the lower movable platform moves upward to make the punch 3.
  • the blank Stretch into the inner mold 4, the blank continues to fill the inner mold 4, forming the horizontal section, at the same time, under the action of the punch, the vertical section pushes the blank upward to form a blind hole, and makes the height of the vertical section 7A reach the size of the forging requirements, see Figure 7.
  • the lower movable platform moves down to the lowest position, the punch 3 is separated from the inner mold 4, and the inner mold 4 and outer jacket 5 on the lower movable platform are disassembled, and the formed blank is taken out. After the blank is completely cooled to room temperature, the formed The final billet is rotated 90° to make the nozzle of the original horizontal section vertically upward, and put it into the support seat 9, and use the local heating device 9 to locally heat the end surface of the original horizontal section within 100mm to 1100°C. 9 can be existing structures such as resistance wire heater.
  • the preparation steps of the blank 6 are as follows: the steel ingot with the as-cast structure is upset, and after the upsetting, it is solidly drawn out, and after the drawing is completed, a part with better quality is taken to obtain a cylindrical blank;
  • the blank 6 is obtained by processing the cylindrical blank.
  • the steel ingot is heated to 1250°C and then subjected to pier thickening and elongation deformation.
  • the original coarse cast structure of the steel ingot is forged and compacted, and the head and tail are cut and the middle section with better quality is used. After machining and ultrasonic inspection, it is used as a blank 6 for forming a forging 7 of a large L-shaped hollow thin-walled pipe.
  • the lower end surface of the processed cylindrical blank 6 is rounded 6A according to 1/5-1/4 of the diameter of the blank 6 .
  • the upper end surface of the blank 6 is chamfered 6B, and the chamfering generally takes R30-50mm.
  • the step of correcting the outer end surface of the horizontal section is: taking out the formed workpiece from the inner mold 4, placing the nozzle of the horizontal section of the formed workpiece vertically upward, and locally heating the end surface of the nozzle of the horizontal section within 100 mm;
  • the upper flat anvil 8 to spread the heating zone, the reduction is 30-50mm, and the amount of the anvil to be spread is 1/4-1/3 of the diameter of the vertical section, and the outer end surface of the horizontal section after punching by the punch 3 is eliminated
  • the formed natural fillets make the size of the horizontal section of the forging meet the requirements of the finished forging.
  • the die forging forming method of a large L-shaped hollow thin-walled pipe disclosed by the invention can accurately control the size of a forging, improve the material utilization rate of the forging, reduce manufacturing costs, greatly shorten the manufacturing cycle, and realize near-net shape.

Abstract

一种大型L形中空薄壁管道的模锻成形模具，包括底模、墩粗杆和冲杆（3），墩粗杆包括平面型墩粗杆（1）和斜面型墩粗杆（2），平面型墩粗杆的模锻工作面为水平设置的平面；斜面型墩粗杆的模锻工作面呈倾斜设置的平面，且沿竖向，斜面型墩粗杆的模锻工作面由与底模的模膛内侧的对应侧至与底模的模膛外侧的对应侧倾斜向下设置；一种大型L形中空薄壁管道的模锻成形方法，包括如下步骤：制取毛坯（6）；预制锻件的竖直段与水平段；修整竖直段的顶端面；成形锻件的竖直段和水平段；修正水平段外端面。模锻成形模具及方法实现了L形中空薄壁管道锻件的精确成形，实现近净成形，提高了材料利用率，增大了各部位的变形程度，提高了锻件的质量。

Description

大型L形中空薄壁管道的模锻成形模具及模锻成形方法 技术领域
本发明属于模锻领域，具体的是大型L形中空薄壁管道的模锻成形模具及模锻成形方法。
背景技术
大型L形中空薄壁管道是核反应堆中带动冷却剂循环的动力装置的核心部件，其结构如图1所示，包括管道竖直段和管道水平段，管道竖直段与管道水平段之间直角转弯，转弯处无大圆角过渡，截面突变，形状异形，整个管道壁薄且尺寸较大，重量达到1t，制造难度非常大。L形中空薄壁管道是管道壁厚小于或者等于管道竖直段直径的1/3的L形管道。
该大型L形中空薄壁管道的传统制造方法为铸造钢锭通过自由锻的方式进行制造，此种制造方式下，锻件本身锻透压实难度大，而且内腔无法锻出，一方面，无形增大了锻件有效截面，增加了锻件质量风险；另一方面，增加了钢锭的锭型，也导致材料利用率降低，锻后加工切削量大，锻件的制造成本与制造周期增加。
为了避免自由锻方式的上述弊端，也出现了模锻的制作方式，即通过模具形成大型L形中空薄壁管道锻件，如图2所示，大型L形中空薄壁管道锻件7与大型L形中空薄壁管道外形相似，大型L形中空薄壁管道锻件7包括相互垂直的竖直段7A和水平段7B，在竖直段7A设置有竖向向下凹陷的盲孔7C。
如：申请号为CN202110006778.3，名称为一种超大型直角弯头的模锻成形模具及模锻成形方法的发明专利申请，公开了一种超大型直角弯头的模锻成形工艺。其在确定直角弯头的形状特征基础上，设计了毛坯形状；用专门的模具，模内锻制成形前毛坯；将毛坯放入另一个专门制作的模膛内，通过镦粗杆及侧堵，成形锻件水平段，并预制竖直段；然后使用冲杆成形锻件带盲孔的竖直段，依次进行调质热处理、半精加工、探伤和精加工后制得该直角弯头。该专利仅仅是提供了一个直角弯头成形的方法，对锻件在水平段与竖直段端面的尺寸控制无法做到精确把控。一方面，该专利在水平管嘴端面设置堵头以预制水平孔，并将堵头设置为向下端面偏心的结构，但该结构同样会极大的影响水平管嘴侧上方的充型效果，使水平管嘴上沿形成非常大的自然圆弧，导致毛坯缺肉。虽然该专利在端面又同时设置了补偿结构(增加端面补偿范围内的模 膛直径)，但缓解毛坯缺肉的效果甚小；另一方面，该方法冲孔成形竖直段后，在厚壁的情况下，可展现一个较好的端面情况，但其忽略了薄壁情况下，端面因摩擦条件差异，将形成一个马蹄形，导致低点一侧锻件毛坯缺肉。
发明内容
本发明的目的是解决目前大型L形中空薄壁管道成形难题，以及竖直段与水平段端面尺寸精确控制难题，大幅提高了材料利用率，实现了L形中空薄壁管道的精确成形。
本发明采用的技术方案是：大型L形中空薄壁管道的模锻成形模具，包括底模、墩粗杆和冲杆，所述底模内设置有与L形中空薄壁管道毛坯的轮廓形状相匹配的模膛，所述墩粗杆包括相互独立设置的平面型墩粗杆和斜面型墩粗杆，所述平面型墩粗杆的模锻工作面为水平设置的平面；所述斜面型墩粗杆的模锻工作面呈倾斜设置的平面，且沿竖向，斜面型墩粗杆的模锻工作面由与底模的模膛内侧的对应侧至与底模的模膛外侧的对应侧倾斜向下设置。
进一步的，所述底模包括内模和外模，所述外模套装于内模外；
所述模膛设置于内模内，包括竖向设置的顶端贯通内模顶壁的竖直模膛段以及水平设置的外端贯通内模侧壁的水平模膛段；所述水平模膛段的外端延伸至外模的内侧面，所述外模的内侧面为竖直的平面，由外模的内侧面封堵水平模膛段的外端构成水平段成型区。
进一步的，内模的水平模膛段的长度为L1，L形中空薄壁管道的锻件水平段长度为L2，则：L1＝L2+30～50mm。
进一步的，斜面型墩粗杆的模锻工作面的最高点与最低点之间的高差为50～100mm。
大型L形中空薄壁管道的模锻成形方法，
根据大型L形中空薄壁管道的零件结构特征设计锻件和模锻成形模具；所述锻件包括竖直段、水平段和设置于竖直段内的盲孔；
制取毛坯；
预制锻件的竖直段与水平段：
将毛坯放入内模的竖直模膛段，使用平面型墩粗杆对毛坯进行初步墩粗，初步墩粗行程为L3＝L0-200mm；所述L0为平面型墩粗杆对毛坯进行墩粗使水平模膛段正好完 全充满所需的行程；
修整竖直段的顶端面：
采用斜面型墩粗杆代替平面型墩粗杆进行精墩粗，精墩粗行程为100mm，使竖直段的顶端面呈有内至外逐步向下倾斜的斜面；
成形锻件的竖直段和水平段：
更换冲杆，竖向向下冲孔形成盲孔，所述盲孔的直径和长度满足锻件成品要求，获得成形锻件；
修正水平段外端面，使水平段外端面呈水平垂直于水平段的平面。
进一步的，毛坯的制取步骤如下：
铸态组织的钢锭进行镦粗、镦粗后进行实心拔长，完成拔长后取用质量较好的部分得到一个圆柱状坯料；
对圆柱状坯料进行加工获取毛坯。
进一步的，所述毛坯呈圆柱状，毛坯的下端面外周呈圆角，所述圆角的直径为毛坯直径的1/5-1/4；毛坯的上端面外周设置有倒角。
进一步的，修正水平段外端面的步骤为：
从内模中取出成形工件，将成形工件的水平段管嘴竖直向上放置，并对水平段管嘴端面100mm内进行局部加热；
使用上平砧对加热区进行展压，压下量为30～50mm，展压进砧量为竖直段直径的1/4-1/3，水平段外端面形成的自然圆角，使锻件水平段尺寸满足锻件成品要求。
本发明的有益效果是：本发明公开的大型L型中空薄壁管道精密成形方法，采用平面型墩粗杆进行初步墩粗后利用斜面型墩粗杆进行精墩粗，使得竖直段的端面得到精确控制；通过平面型墩粗杆、斜面型墩粗杆和冲杆成形后使坯料充满水平模膛段，使得水平段的端面得到精确控制，从而实现了L形中空薄壁管道锻件的精确成形，实现近净成形，提高了材料的利用率，降低制造成本，大大缩短制造周期。
通过毛坯制作时的墩粗拔长，使原始的钢锭通过镦粗拔长后，组织变得致密。后续的对水平段的端面进行展压过程再次进行压实，从而增大了各部位的变形程度，强化了压实效果，降低了锻件的质量风险。
附图说明
图1为大型L形中空薄壁管道的剖面图；
图2为大型L形中空薄壁管道锻件的剖面图；
图3为大型L形中空薄壁管道的模锻成形模具结构示意图；
图4为毛坯示意图；
图5为采用本发明的模锻成形模具进行初步墩粗的示意图；
图6为采用本发明的模锻成形模具进行二次墩粗的示意图；
图7为采用本发明的模锻成形模具进行冲孔的示意图；
图8为L0标记示意图；
图9水平段加热主视图；
图10水平段端面展压主视图；
图11为图10的右视图。
图中，平面型墩粗杆1、斜面型墩粗杆2、冲杆3、内模4、竖直模膛段4A、水平模膛段4B、外模5、毛坯6、圆角6A、倒角6B、锻件7、竖直段7A、水平段7B、盲孔7C、上平砧8、加热装置9。
具体实施方式
下面结合附图对本发明做进一步的说明如下：
大型L形中空薄壁管道的模锻成形模具，如图3所示，包括底模、墩粗杆和冲杆3，所述底模内设置有与L形中空薄壁管道毛坯的轮廓形状相匹配的模膛，所述墩粗杆包括相互独立设置的平面型墩粗杆1和斜面型墩粗杆2，所述平面型墩粗杆1的模锻工作面为水平设置的平面；所述斜面型墩粗杆2的模锻工作面呈倾斜设置的平面，且沿竖向，斜面型墩粗杆2的模锻工作面由与底模的模膛内侧的对应侧至与底模的模膛外侧的对应侧倾斜向下设置。
现有超大型直角弯头的模锻成形模具，其墩粗杆仅有一种类型，即模锻工作面水平设置的水平面型墩粗杆，采用该墩粗杆完成整个模锻过程的墩粗作业，墩粗工序完成后的端面为水平面，在后续冲杆3冲孔成形过程中，坯料向上反挤成孔，由于孔壁较薄，内外两侧摩擦条件差异，导致原来的水平端面变成马蹄形，使锻件毛坯低点一侧缺肉。
如图5、6和7所示，本发明公开的大型L形中空薄壁管道的模锻成形模具，通过设置模锻工作面呈水平平面的平面型墩粗杆1和模锻工作面呈斜面的斜面型墩粗杆2配合工作，可先使用平面型墩粗杆1初步墩粗，预制锻件7的竖直段7A和水平段7B， 然后再利用斜面型墩粗杆2进行墩粗，使竖直段7A的顶面呈由内侧向外侧倾斜向下的斜面，来弥补两侧摩擦条件差异，使得在后续冲杆3冲孔成形过程中，缓解冲孔成形后竖直段端面马蹄状程度，尽量使坯料向上流动至同样的高度，使竖直段7A的端面尺寸得到精准控制。
现有超大型直角弯头的模锻成形模具，其内模4的水平模膛段4B的外端设置堵头，会使得锻件7的水平段7B的上沿形成较大的自然圆弧，导致水平段7B外端缺肉，为了避免水平段7B外端面充型不饱满的问题，本发明中，所述底模包括内模4和外模5，所述外模5套装于内模4外；所述模膛设置于内模4内，包括竖向设置的顶端贯通内模4顶壁的竖直模膛段4A以及水平设置的外端贯通内模4侧壁的水平模膛段4B；所述水平模膛段4B的外端延伸至外模5的内侧面，所述外模5的内侧面为竖直的平面，由外模5的内侧面封堵水平模膛段4B的外端构成水平段成型区。即，水平模膛段4B内取消堵头，直接采用外模5的内侧面作为封堵，则水平段7B端头处形成的自然圆角比设置堵头时大大缩小，更利于消除水平段7B端面形成的自然圆角。
因水平端面在填充过程中不可避免产生自然圆角，若内模4的水平模膛段4B的长度等于锻件水平段长度，定然会造成毛坯缺肉。为了能有效消除自然圆角，最优的，内模4的水平模膛段4B的长度为L1，L形中空薄壁管道的锻件水平段长度为L2，则：L1＝L2+30～50mm。
优选的，斜面型墩粗杆2的模锻工作面的最高点与最低点之间的高差为50～100mm。
大型L形中空薄壁管道的模锻成形方法，
根据大型L形中空薄壁管道的零件结构特征设计锻件7和所述的模锻成形模具；所述锻件7包括竖直段7A、水平段7B和设置于竖直段7A内的盲孔7C。
制取毛坯6；
预制锻件的竖直段与水平段：
将毛坯6放入内模4的竖直模膛段4A，使用平面型墩粗杆1对毛坯6进行初步墩粗，初步墩粗行程为L3＝L0-150-250mm；如图8所示，所述L0为平面型墩粗杆1对毛坯6进行墩粗使水平模膛段4B正好完全充满所需的行程；
修整竖直段的顶端面：
采用斜面型墩粗杆2代替平面型墩粗杆1进行精墩粗，精墩粗行程为100mm，使 竖直段的顶端面呈有内至外逐步向下倾斜的斜面；
成形锻件的竖直段和水平段：
更换冲杆3，竖向向下冲孔形成盲孔7C，所述盲孔7C的直径和长度满足锻件成品要求，获得成形锻件；
修正水平段外端面，使水平段外端面呈水平垂直于水平段的平面。
平面型墩粗杆1、斜面型墩粗杆2、冲杆3按图2所示进行装配后，固定于压机的上活动平台上；内模4、外模5按图2所示进行装配后，固定于压机下活动平台上，下活动平台水平向左滑动至工作区间之外，将加热后的成形毛坯6放置于内模4中，下活动平台水平向右滑动至平面型墩粗杆1的正下方使内模4的竖直模膛段4A与平面型墩粗杆1中心轴线重合，下活动平台向上移动使平面型墩粗杆1伸入内模4中，对成形毛坯6进行模内镦粗，此次模内镦粗的行程＝镦粗使水平段完全充满的行程-200mm，预制锻件7的竖直段7A和水平段7B，如图5所示。
下活动平台向下移动至最低位置，平面型墩粗杆1脱离内模4，上活动平台向左滑动使斜面型墩粗杆2与内模4竖直段中心轴线重合，斜面型墩粗杆2的底面上与内模4外侧相对的为底面的低点，与内模4内侧相对的为底面的低点高点。下活动平台向上移动使斜面型墩粗杆2伸入内模4中，对成形坯料进行模内镦粗，此次模内镦粗的行程为100mm，坯料继续填充内模4水平段，同时将竖直段7A的端面预制成内侧高，外侧低的斜面，如图6所示，
下活动平台向下移动至最低位置，斜面型墩粗杆2脱离内模4，上活动平台向左滑动使冲杆3与内模4竖直段中心轴线重合，下活动平台向上移动使冲杆3伸入内模4中，坯料继续填充内模4，成形水平段，同时，竖直段在冲杆的作用下使坯料向上反挤形成一个盲孔，并使竖直段7A高度达到锻件尺寸要求，见图7。
下活动平台向下移动至最低位置，冲杆3脱离内模4，并将下移动平台上的内模4、外套5拆开，取出成形后的坯料，待坯料完全冷却至室温后，将成形后的坯料旋转90°，使原水平段管嘴竖直向上，并将其放入支撑座9中，采用局部加热装置9对原水平段端面100mm范围内进行局部加热至1100℃，局部加热装置9可以为电阻丝加热器等现有结构。
取出局部加热装置，对加热后的原水平段端面使用上平砧8进行展压，压下量为30～50mm，展压的进砧量为竖直段直径的1/4-1/3，消除在模内成形时端面残留的自 然圆角，使原水平段尺寸满足锻件要求。最终获得全结构特征仿形成形、各部位尺寸满足要求、表面质量良好的大型L形中空薄壁管道，如图10和图11所示。
其中，毛坯6的制取步骤如下：铸态组织的钢锭进行镦粗、镦粗后进行实心拔长，完成拔长后取用质量较好的部分得到一个圆柱状坯料；
对圆柱状坯料进行加工获取毛坯6。
如选用低合金钢的钢锭，钢锭加热至1250℃后进行墩粗、拔长变形，将钢锭原始粗大铸态组织锻透压实，并进行切头去尾，取用质量较好的中间段，经过机加工并进行超声波检查合格后作为毛坯6，用于成形大型L形中空薄壁管道的锻件7。
为了保证成形过程中毛坯6充型顺利，加工后的圆柱状的毛坯6下端面按毛坯6直径的1/5-1/4进行倒圆角6A。毛坯6上端面为了避免应力集中，进行倒角6B，倒角一般取R30～50mm即可。
优选的，修正水平段外端面的步骤为：从内模4中取出成形工件，将成形工件的水平段管嘴竖直向上放置，并对水平段管嘴端面100mm内进行局部加热；
使用上平砧8对加热区进行展压，压下量为30～50mm，展压进砧量为竖直段直径的1/4-1/3，消除冲杆3冲孔后水平段外端面形成的自然圆角，使锻件水平段尺寸满足锻件成品要求。通过对水平段7B的管嘴端面进行展压，强化了压实效果，降低了锻件的质量风险。本发明公开的大型L形中空薄壁管道的模锻成形方法，能精准控制锻件的尺寸，提高锻件材料利用率，降低制造成本，大大缩短制造周期，实现近净成形。

Claims (9)

  1. 大型L形中空薄壁管道的模锻成形模具，包括底模、墩粗杆和冲杆(3)，所述底模内设置有与L形中空薄壁管道毛坯的轮廓形状相匹配的模膛，其特征在于：所述墩粗杆包括相互独立设置的平面型墩粗杆(1)和斜面型墩粗杆(2)，所述平面型墩粗杆(1)的模锻工作面为水平设置的平面；所述斜面型墩粗杆(2)的模锻工作面呈倾斜设置的平面，且沿竖向，斜面型墩粗杆(2)的模锻工作面由与底模的模膛内侧的对应侧至与底模的模膛外侧的对应侧倾斜向下设置。
  2. 如权利要求1所述的大型L形中空薄壁管道的模锻成形模具，其特征在于：所述底模包括内模(4)和外模(5)，所述外模(5)套装于内模(4)外；
    所述模膛设置于内模(4)内，包括竖向设置的顶端贯通内模(4)顶壁的竖直模膛段(4A)以及水平设置的外端贯通内模(4)侧壁的水平模膛段(4B)；所述水平模膛段(4B)的外端延伸至外模(5)的内侧面，所述外模(5)的内侧面为竖直的平面，由外模(5)的内侧面封堵水平模膛段(4B)的外端构成水平段成型区。
  3. 如权利要求2所述的大型L形中空薄壁管道的模锻成形模具，其特征在于：内模(4)的水平模膛段(4B)的长度为L1，L形中空薄壁管道的锻件水平段长度为L2，则：L1＝L2+30～50mm。
  4. 如权利要求1-3任意一项权利要求所述的大型L形中空薄壁管道的模锻成形模具，其特征在于：斜面型墩粗杆(2)的模锻工作面的最高点与最低点之间的高差为50～100mm。
  5. 大型L形中空薄壁管道的模锻成形方法，其特征在于：
    根据大型L形中空薄壁管道的零件结构特征设计锻件(7)和如权利要求4所述的模锻成形模具；所述锻件(7)包括竖直段(7A)、水平段(7B)和设置于竖直段(7A)内的盲孔(7C)；
    制取毛坯(6)；
    预制锻件的竖直段与水平段：
    将毛坯(6)放入内模(4)的竖直模膛段(4A)，使用平面型墩粗杆(1)对毛坯(6)进行初步墩粗，初步墩粗行程为L3＝L0-(150-250)mm；所述L0为平面型墩粗杆(1)对毛坯(6)进行墩粗使水平模膛段(4B)正好完全充满所需的行程；
    修整竖直段的顶端面：
    采用斜面型墩粗杆(2)代替平面型墩粗杆(1)进行精墩粗，精墩粗行程为100mm，使竖直段的顶端面呈有内至外逐步向下倾斜的斜面；
    成形锻件的竖直段和水平段：
    更换冲杆(3)，竖向向下冲孔形成盲孔(7C)，所述盲孔(7C)的直径和长度满足锻件成品要求，获得成形锻件；
    修正水平段外端面，使水平段外端面呈水平垂直于水平段的平面。
  6. 如权利要求5所述的大型L形中空薄壁管道的模锻成形方法，其特征在于：毛坯(6)的制取步骤如下：
    铸态组织的钢锭进行镦粗、镦粗后进行实心拔长，完成拔长后取用质量较好的部分得到一个圆柱状坯料；
    对圆柱状坯料进行加工获取毛坯(6)。
  7. 如权利要求6所述的大型L形中空薄壁管道的模锻成形方法，其特征在于：所述毛坯(6)呈圆柱状，毛坯(6)的下端面外周呈圆角(6A)，所述圆角(6A)的直径为毛坯(6)直径的1/5-1/4；毛坯(6)的上端面外周设置有倒角(6B)。
  8. 如权利要求5所述的大型L形中空薄壁管道的模锻成形方法，其特征在于：修正水平段外端面的步骤为：
    从内模(4)中取出成形工件，将成形工件的水平段管嘴竖直向上放置，并对水平段管嘴端面100mm内进行局部加热；
    使用上平砧(8)对加热区进行展压，压下量为30～50mm，展压进砧量为竖直段直径的1/4-1/3，消除水平段外端面形成的自然圆角，使锻件水平段尺寸满足锻件成品要求。
  9. 如权利要求5所述的大型L形中空薄壁管道的模锻成形方法，其特征在于：所述大型L形中空薄壁管道锻件的管壁厚度小于或者等于竖直段(7A)直径的1/3。
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